tow DAEWOO LACETTI 2004 Service Owner's Manual

ENGINE CONTROLS 1F – 583
DAEWOO V–121 BL4
HESITATION, SAG, STUMBLE
Definition : Involves a momentary lack of response as the
accelerator is pushed down. This can occur at any vehicle
speed. It is usually the most severe when first trying to
make the vehicle move, as from a stop. Hesitation, sag,
or stumble may cause the engine to stall if severe enough.Important : Before diagnosing this condition, check ser-
vice bulletins for Programmable Read–Only Memory
(PROM) updates.
Step
ActionValue(s)YesNo
1Were the Important Preliminary Checks performed?–Go toStep 2Go to
”Important Pre-
liminary
Checks”
21. Check the fuel system pressure. If the pres-
sure is not within the value specified, service
the fuel system as needed.
2. Inspect the Throttle Position (TP) sensor for
binding or sticking. The TP sensor voltage
should increase at a steady rate as the throttle
is moved toward Wide Open Throttle (WOT).
Is the problem found?41–47 psi
(284–325 kPa)Go toStep 3Go toStep 4
3Repair or replace any components as needed.
Is the repair complete?–System OK–
41. Check the Manifold Absolute Pressure (MAP)
sensor response and accuracy.
2. Inspect the fuel for water contamination.
3. Check the Evaporative (EVAP) Emission canis-
ter purge system for proper operation.
Is the problem found?–Go toStep 5Go toStep 6
5Repair or replace any components as needed.
Is the repair complete?–System OK–
61. Disconnect all of the fuel injector harness con-
nectors.
2. Connect an injector test light between the har-
ness terminals of each fuel injector.
3. Note the test light while cranking the engine.
Does the test light blink on all connectors?–Go toStep 8Go toStep 7
71. Repair or replace the faulty fuel injector drive
harness, the connector, or the connector termi-
nal.
2. If the connections and the harnesses are good,
replace the engine control module (ECM) for
an internal open in the fuel injector driver cir-
cuit.
Is the repair complete?–System OK–
8Measure the resistance of each fuel injector. The re-
sistance will increase slightly at higher tempera-
tures.
Is the fuel injector resistance within the value speci-
fied?11.6–12.4 ΩGo toStep 10Go toStep 9
9Replace any of the fuel injectors with a resistance
that is out of specifications.
Is the repair complete?–System OK–
10Perform an injector balance test.
Is the problem found?–Go toStep 11Go toStep 12

2B – 10IWHEEL ALIGNMENT
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
FOUR WHEEL ALIGNMENT
The first responsibility of engineering is to design safe
steering and suspension systems. Each component must
be strong enough to withstand and absorb extreme pun-
ishment. Both the steering system and the front and the
rear suspension must function geometrically with the body
mass.
The steering and the suspension systems require that the
front wheels self–return and that the tire rolling effort and
the road friction be held to a negligible force in order to al-
low the customer to direct the vehicle with the least effort
and the most comfort.
A complete wheel alignment check should include mea-
surements of the rear toe and camber.
Four–wheel alignment assures that all four wheels will be
running in precisely the same direction.
When the vehicle is geometrically aligned, fuel economy
and tire life are at their peak, and steering and perfor-
mance are maximized.
TOE
Toe–in is the turning in of the tires, while toe–out is the
turning out of the tires from the geometric centerline or
thrust line. The toe ensures parallel rolling of the wheels.
The toe serves to offset the small deflections of the wheel
support system which occur when the vehicle is rolling for-
ward. The specified toe angle is the setting which achieves
0 degrees of toe when the vehicle is moving.
Incorrect toe–in or toe–out will cause tire wear and re-
duced fuel economy. As the individual steering and sus-
pension components wear from vehicle mileage, addition-
al toe will be needed to compensate for the wear.
Always correct the toe dimension last.
CASTER
Caster is the tilting of the uppermost point of the steering
axis either forward or backward from the vertical when
viewed from the side of the vehicle. A backward tilt is posi-
tive, and a forward tilt is negative. Caster influences direc-
tional control of the steering but does not affect tire wear.
Weak springs or overloading a vehicle will affect caster.
One wheel with more positive caster will pull toward the
center of the car. This condition will cause the car to move
or lean toward the side with the least amount of positive
caster. Caster is measured in degrees and is not adjust-
able.
CAMBER
Camber is the tilting of the top of the tire from the vertical
when viewed from the front of the vehicle. When the tires
tilt outward, the camber is positive. When the tires tilt in-
ward, the camber is negative. The camber angle is mea-
sured in degrees from the vertical. Camber influences
both directional control and tire wear.
If the vehicle has too much positive camber, the outside
shoulder of the tire will wear. If the vehicle has too much
negative camber, the inside shoulder of the tire will wear.
Camber is not adjustable.
STEERING AXIS INCLINATION
Steering Axis Inclination (SAI) is the tilt at the top of the
steering knuckle from the vertical. Measure the SAI angle
from the true vertical to a line through the center of the strut
and the lower ball joint as viewed from the front of the ve-
hicle.
SAI helps the vehicle track straight down the road and as-
sists the wheel back into the straight ahead position. SAI
on front wheel drive vehicles should be negative.
INCLUDED ANGLE
The included angle is the angle measured from the cam-
ber angle to the line through the center of the strut and the
lower ball joint as viewed from the front of the vehicle.
The included angle is calculated in degrees. Most align-
ment racks will not measure the included angle directly. To
determine the included angle, subtract the negative or add
the positive camber readings to the Steering Axis Inclina-
tion (SAI).
SCRUB RADIUS
The scrub radius is the distance between true vertical and
the line through the center of the strut and lower ball joint
to the road surface. Scrub radius is built into the design of
the vehicle. Scrub radius is not adjustable.
SETBACK
The setback is the distance in which one front hub and
bearing assembly may be rearward of the other front hub
and bearing assembly. Setback is primarily caused by a
road hazard or vehicle collision.
TURNING ANGLE
The turning angle is the angle of each front wheel to the
vertical when the vehicle is making a turn.

TIRES AND WHEELS 2E – 9
DAEWOO V–121 BL4
GENERAL DESCRIPTION
AND SYSTEM OPERATION
TIRE AND WHEEL BALANCING
There are two types of tire and wheel balancing: static and
dynamic.
Static balance is the equal distribution of weight around
the wheel. Assemblies that are statically unbalanced
cause a bouncing action called wheel tramp. This condi-
tion may eventually cause uneven tire wear.
Dynamic balance is the equal distribution of weight on
each side of the centerline so that when the assembly
spins there is no tendency for it to move from side to side.
Assemblies that are dynamically unbalanced may cause
wheel shimmy.
General Balance Precautions
Remove all deposits of foreign material from the inside of
the wheel.
CAUTION : Remove stones from the tread in order to
avoid operator injury during spin balancing.
Inspect the tire for any damage. Balance the tire according
to the equipment manufacturer’s recommendations.
Wheel Weights
If more than 85 grams (3.0 ounces) are needed to static
balance the wheel, split the wheel weights as equally as
possible between the inboard and the outboard flanges.
Balancing the assemblies with factory alloy wheels re-
quires the use of special nylon–coated, clip–on wheel
weights. These weights are designed to fit over the thicker
rim flange of the alloy wheel. Install these weights with a
plastic–tipped hammer.
Adhesive wheel weights are also available. Use the follow-
ing procedure to install adhesive wheel weights
Adhesive Wheel Weight Installation
1. Clean the wheel by sanding it to bare alloy where
the wheel weight will be installed.
2. Use a clean cloth or paper towel saturated with a
mixture of half isopropyl alcohol and half water to
wipe the place where the wheel weight will be
installed.
3. Dry the area with hot air. The surface of the wheel
should be warm to the touch.
4. Warm the adhesive backing on the wheel weights
to room temperature.
5. Remove the tape from the back of the weights. Do
not touch the adhesive surface.
6. Apply the the wheel weight and press it on with
hand pressure.
7. Secure the wheel weight with a 70–110 N (16–25
lb) force applied with a roller.
TIRE CHAIN USAGE
Due to limited tire–to–body clearance on certain vehicles,
recommendations for tire chain use are published in the
Owner ’s Manual. When tire chains need to be used, most
current Daewoo vehicles require SAE Class ”S” tire
chains. These may also be designated as 1100 Series,
type PL tire chains. These chains are specifically designed
to limit the ”fly off” effect which occurs when the wheel ro-
tates.
Be sure that only fine–link chains are used which do not
add more than 15 mm (0.590 inch), including the lock, to
the tread surface and the inner sides of the tires. Manufac-

HYDRAULIC BRAKES 4A – 13
DAEWOO V–121 BL4
8. Attach the bleeder hose to the bleeder valve. Sub-
merge the opposite end of the hose in a clean con-
tainer partially filled with brake fluid.
9. Open the bleeder valve one–half to three–fourths
turn and allow the fluid to flow until no air is seen in
the fluid.
Notice : After the bleeding operation, the brake reservoir
may be pressurized. While disconnecting the bleeder
hose or the unthreaded adapter cap, cover the cap and the
connection with a shop towel to protect painted surfaces
from contact with the brake fluid.
10. Inspect the brake pedal for sponginess. Repeat the
entire bleeding procedure to correct this condition.
BRAKE HOSE REAR
Removal Procedure
1. Raise and suitably support the vehicle.
2. Remove the brake hose retainer.
3. Disconnect the brake pipe line from the disc brake
hose.
4. Remove the rear disc brake hose retainer and the
brake hose from the bracket on the steering
knuckle shaft.

4E1 – 10IREAR DISC BRAKES
DAEWOO V–121 BL4
UNIT REPAIR
CALIPER OVERHAUL
1. Remove the caliper. Refer to ”Caliper” in this sec-
tion.
CAUTION : Do not attempt to catch the piston when
attempting to remove the piston with compressed air.
The piston will pop out of its bore with enough force
to damage a hand or fingers.
Important : When removing the caliper piston with com-
pressed air, place some rolled–up shop towels beneath
the caliper to prevent damage to the piston.
2. Apply unlubricated compressed air at the hose inlet
of the caliper.
3. Remove the piston from its bore and remove the
piston dust seal.
4. Remove the inner seal from the bore. Avoid
scratching the bore.
5. Remove the bleeder valve dust cap and the bleeder
valve.
Assembly Procedure
Important : Do not use a hone or any other procedure to
remove material from the caliper bore or the piston.
1. Clean all parts in denatured alcohol or brake fluid.
Dry the parts with unlubricated compressed air and
blow out all passages in the housing and the bleed-
er valve.
2. Inspect the piston and caliper for scoring, nicks, or
corrosion. Replace any components which show
these conditions.

4E2 – 6IREAR DRUM BRAKES
DAEWOO V–121 BL4
7. Position the leading shoe and the adjuster assem-
bly against the backing plate.
8. Fasten the lower return spring to the leading shoe.
9. Install the adjuster assembly.
10. Turn the adjuster in as far as possible.
11. Position the spring clip toward the backing plate.
12. Install the leading shoe with the hold–down spring.
13. Attach the leading shoe upper link–spring connec-
tion, which applies tension to the upper return
spring.
Notice : Do not overstretch the upper return spring.
14. Install the upper return spring from the spring con-
necting link to the brake shoe.
Notice : The nut must not lock firmly at the end of the ad-
justment assembly.
15. Before installing the brake drum, make sure the
adjuster assembly nut is drawn all the way to the
stop.

4F – 62IANTILOCK BRAKE SYSTEM
DAEWOO V–121 BL4
FRONT WHEEL SPEED SENSOR
Removal Procedure
1. Disconnect the negative battery cable.
2. Disconnect the front wheel speed sensor electrical
connector.
3. Raise and suitably support the vehicle.
4. Remove the wheel. Refer to Section 2E, Tires and
Wheels.
5. Turn the steering wheel to expose the speed sen-
sor. It is located at the rear of the steering knuckle
near the tie rod end.
6. Remove the bolt and the front wheel speed sensor
from the steering knuckle.
7. Free the feedthrough grommet for the speed sen-
sor harness and the hydraulic pipe from the strut
tower. Remove the speed sensor harness from it so
that the connector can pass through the hole in the
strut tower.
8. Free the sensor harness from the grommet holders
and the clamps and pull it through the fender.
Installation Procedure
1. Install the front wheel speed sensor to the steering
knuckle. Secure it with the bolt.
Tighten
Tighten the front wheel speed sensor bolt to 8 NSm
(71 lb–in).
2. Feed the sensor harness into the engine compart-
ment, insert it into the grommet, and secure the
grommet into the hole in the strut tower.
3. Secure the harness into the grommet holders and
the clamps under the fender.
4. Install the wheel. Refer to Section 2E, Tires and
Wheels.
5. Lower the vehicle.
6. Connect the front wheel speed sensor electrical
connector.
7. Connect the negative battery cable.

5A1 – 46IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
sible, drive the vehicle for a few kilometers (N–D,
N–R, shift until two gear). This will allow the trans-
axle to be within the correct temperature range.
Transaxle fluid level should be checked at tempera-
ture 20 to 45°C (68 to 113°F).
CAUTION : Removal of the fluid filler plug when the
transaxle fluid is hot may cause injury if fluid drains
from the filler hole.
2. Switch off accessories, especially air conditioner,
heater.
3. With the brake pedal pressed, move the gear shift
control lever through the gear ranges, pausing a
few seconds in each range. Return the gearshift
lever to P(Park). Turn the engine OFF.
4. Park the vehicle on a hoist, inspection pit or similar
raised level surface. The vehicle must be level to
obtain a correct fluid level measurement.
5. Place a fluid container below the fluid filler plug.
6. Clean all dirt from around the fluid filler plug.
Remove the fluid filler plug. Clean the filler plug and
check that there is no damage to the ”O” ring.
S If fluid drains through the filler hole the transaxle
may have been overfilled. When the fluid stops
draining the fluid level is correct. Install the fluid
filler plug and tighten it to 45NSm(34 lb–ft).
S If fluid does not drain through the filler hole, the
transaxle fluid level may be low. Lower the ve-
hicle, and start the vehicle in P(Park) with the
parking brake and the brake applied. With the
engine idling, move the gear shift lever through
the gear ranges, pausing a few seconds in each
range and adding the fluid until gear application
is felt. Return the gear shift lever to P(Park).
Turn the engine OFF and raise the vehicle.
Check if the fluid level is aligned with the bottom
of the filler hole. If not, add a small quantity of
fluid to the correct level. Install the fluid filler
plug and tighten it to 45NSm(34 lb–ft).
7. When the fluid level checking procedure is com-
pleted, wipe any fluid around the filler plug with a
rag or shop towel.
Fluid Level Set After Service
1. Depending on the service procedure performed,
add the following amounts of fluid through the filler
plug hole prior to adjusting the fluid level:
Oil pan removal – 4 liters (4.23 quarts)
Converter removal – 2 liters ( 2.11 quarts)
Overhaul – 6.9liters (7.3 quarts)
Oil drain plug removal – 4 liters (4.23 quarts)
2. Follow steps 1 through 4 of the Fluid Level Diagno-
sis Procedure.
3. Clean all dirt from around the fluid filler plug.
Remove the fluid filler plug. Clean the filler plug and
check that there is no damage to the ”O” ring.
4. Lower the vehicle with the filler plug still removed
and start the vehicle in P(Park) with the parking
brake and the brake applied. With the engine idling,move the gear shift lever through the gear ranges,
pausing a few seconds in each range and adding
the fluid until gear application is felt. Then add an
additional 0.5 liters of fluid. Return the gear shift
lever to P(Park). Turn the engine OFF and raise the
vehicle. Install the fluid filler plug and tighten it to
45NSm (34 lb–ft).
5. Drive the vehicle at 2.2 miles(3.5km) to 2.8
miles(4.5 km) with light throttle so that the engine
does not exceed 2500 rpm. This should result in
the transaxle temperature being in the range 20 to
45°C (68 to 11°F). With the brake applied, move
the shift lever through the gear ranges, pausing a
few seconds in each range at the engine idling.
6. Return the gear shift lever to P(Park). Turn the en-
gine OFF and raise the vehicle on the hoist, if appli-
cable, ensuring the vehicle is level. When the three
minutes passed after the engine stopped, remove
the filler plug. Check if the fluid level is aligned with
the bottom of the filler hole. If not, add a small
quantity of fluid to the correct level. Install the fluid
filler plug and tighten it to 45NSm (34 lb–ft).
7. Wipe any fluid around the filler plug with a rag or
shop towel.
Fluid Leak Diagnosis and Repair
The cause of most external leaks can generally be Lo-
cated and repaired with the transaxle in the vehicle.
Methods for Locating Leaks
General Method
1. Verify that the leak is transaxle fluid.
2. Thoroughly clean the suspected leak area.
3. Drive the vehicle for approximately 25 km (15
miles) or until the transaxle reaches normal operat-
ing temperature (88°C, 190°F).
4. Park the vehicle over clean paper or cardboard.
5. Turn the engine OFF and look for fluid spots on the
paper.
6. Make the necessary repairs to correct the leak.
Powder Method
1. Thoroughly clean the suspected leak area.
2. Apply an aerosol type powder (foot powder) to the
suspected leak area.
3. Drive the vehicle for approximately 25 km (15
miles) or until the transaxle reaches normal operat-
ing temperature (88°C, 190°F).
4. Turn the engine OFF.
5. Inspect the suspected leak area and trace the leak
path through the powder to find the source of the
leak.
6. Make the necessary repairs.
Dye and Black Light Method
1. Add dye to the transaxle though the transaxle fluid
filler plug. Follow the manufacturer’s recommenda-
tion for the amount of dye to be used.
2. Use the black light to find the fluid leak.
3. Make the necessary repairs.

ZF 4 HP 16 AUTOMATIC TRANSAXLE 5A1 – 191
DAEWOO V–121 BL4
6. Check the oil fluid level. If fluid does not drain
through the plug hole after adding a total of 4 liters,
then the transaxle was either underfilled or the
transaxle is leaking fluid. Inspect the transaxle for
fluid leaks. Fix any leaks before setting the trans-
axle fluid level.
7. Install the fluid level plug using the plug remover/in-
staller DW260–070.
Tighten
Tighten the Plug to 45 NSm (33 lb–ft).
8. When the fluid level checking procedure is com-
pleted, wipe any fluid from the transaxle case with a
rag or shop towel. Also, check that the fluid fill cap
and the vent tube are properly installed.
CHANGING THE FLUID
Tools Required
DW260–070 Plug Remover/Installer
Removal and Installation Procedure
1. Raise and suitably support the vehicle.
2. Place a fluid container below the fluid drain plug.
3. Remove the transaxle fluid drain plug using the
plug remover/installer DW260–070.
Tighten
Tighten the Plug to 45 NSm (33 lb–ft).
4. Adding transaxle fluid. Refer to ”Transaxle Fluid
Level Checking Procedure” in this section.
5. Connect the negative battery cable.

5A1 – 192IZF 4 HP 16 AUTOMATIC TRANSAXLE
DAEWOO V–121 BL4
FLUID LEVEL SET AFTER SERVICE
1. Add transaxle fluid through the fill cap hole prior to
adjusting the fluid level. The amount of fluid to add
should be based on the type of service done.
Adjustment Notice
S Use ESSO LT 71141 transaxle fluid only.
S Oil pan removed : 4L (4.2 qt)
S Torque converter removed : 2L (2.1 qt)
S Complete overhaul : 6.7L (7.1qt)
S Drain plug removed : 4L (4.2 qt)
2. Check the transaxle fluid level. Refer to ”Transaxle
Fluid Level Checking Procedure” in this section.
3. Add additional fluid through the fill cap hole in 0.5
liter (0.5 quart) increments until the fluid comes out
through the plug hole.
4. Allow the fluid to finish draining out through the plug
hole, then install the fluid level plug.
5. When the fluid level setting procedure is completed,
wipe any fluid from the transaxle case with a rag or
shop towel. Also, check that the fluid fill cap and the
vent tube are properly installed.
REPAIRING FLUID LEAKS
Locating Leaks
General Method
1. Verify that the leak is transaxle fluid.
2. Thoroughly clean the suspected leak area.
3. Operate the vehicle for about 25 kilometers (15
miles) or until the transaxle reaches normal operat-
ing temperature, 88°C (190°F).
4. Park the vehicle over clean paper or cardboard.
5. Turn the engine off and look for fluid spots on the
paper.
6. Make the necessary repairs to correct the leak.
Powder Method
1. Thoroughly clean the suspected leak area.
2. Apply an aerosol–type powder (foot powder) to the
suspected leak area.
3. Operate the vehicle for about 25 kilometers (15
miles) or until the transaxle reaches normal operat-
ing temperature, 88°C (190°F).
4. Turn the engine off.
5. Inspect the suspected leak area and trace the leak
path through the powder to find the source of the
leak.
6. Make the necessary repairs.